Remove/install alternator

AR15.40-P-5032GI

Remove/install alternator

14.2.12

 

Remove/install

 Danger!

Risk of explosion caused by escaping oxyhydrogen gas. Risk of injury caused by caustic burns to eyes, skin and mucous membranes from battery electrolyte (contains diluted sulfuric acid) or metal spatter due to short circuit. Risk of burn injuries caused by short circuit. Risk of poisoning caused by swallowing battery electrolyte (contains diluted sulfuric acid) or absorption of lead over the skin or orifices

No fire, sparks, open flames or smoking.

Wear acid-resistant gloves and clothing and safety glasses with side guards.

Do not place any conductive objects on the battery and avoid any short circuit from battery positive to ground.

Only fill liquid battery electrolyte (diluted sulfuric acid) into suitable and appropriately marked containers.

AS54.10-Z-0001-01A

1

Disconnect battery ground line

 Insulate cable terminal of ground lead to prevent unintentional contact between the disconnected ground lead and ground point W16/4

AR54.10-P-0003A

2

Remove inner fender in right front fender

AR88.10-P-1300GH

3

Remove soundproofing

4

Disconnect clutch (2) and screw off electrical cable on the alternator

5

Lock electrical cable in terminal 30 (3) and screw out screws (4)

 Remove cover sleeve above electric cable terminal 30 (3), if present.

 Danger!

Risk of injury to skin and eyes caused by scalding from contact with hot coolant spray. Risk of poisoning caused by swallowing coolant.

Do not open cooling system unless coolant temperature is below 90°C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.

Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A

6

Drain cooling fluid

AR20.00-P-1142HA

7

Remove air filter housing

8

Slacken poly-V belt and take off

AR13.22-P-1202HB

9

Screw out bolts (5) and remove the oil line to the turbocharger (7)



*BA09.40-P-1004-01C

10

Remove cooler feed line (6)

 Installation: Use new seals (12).

11

Remove bolts (9) and remove bracket (10)

12

Remove bolt (11) from pulsation damper bracket

13

Remove bolts (8) of cooler housing (1)



*BA15.40-P-1006-01D

14

Remove alternator (G2) downwards complete with cooler housing (1)

 Installation: Insert new seal (13) between cooler housing flange and engine housing.

 If alternator (G2) is leaking, unscrew the alternator on the coolant housing and replace the O-ring.

15

Install in the reverse sequence

Number

Designation

Engine 612.961/
963

BA09.40-P-1004-01C

Oil feed line to turbocharger

Screw socket

Nm

30

Banjo bolt

Nm

18

Number

Designation

Engine
611, 612

BA15.40-P-1006-01D

Bolt, cooler housing of alternator to crankcase

M7

Nm

-

M8

Nm

20